Flexible reinforced board

ABSTRACT

A sports board includes an elongated foam core, a top layer, a bottom layer and at least one flexible flat reinforcement strip. The top layer is laminated to an upper surface of the foam core and has a riding surface, a thickness less than that of the foam core and a density greater than the foam core. The bottom layer is laminated to a lower surface of the foam core and has a running sole, a thickness less than that of the foam core and a density greater than the foam core. In particular, the flexible flat reinforcement strip is embedded in a lower half of the foam core and extends substantially the whole length of the foam core and parallel to the foam core.

BACKGROUND OF INVENTION

1. Field of Invention

The present invention relates to foam sports boards, such as surfboards or bodyboards and the like and in particularly directed to flexible reinforced boards.

2. Related Prior Art

Bodyboards for riding waves and other recreational sports boards made of foam or other flotation material are known in the prior art. In general, such sports boards are composed of a number of layers thermally or adhesively bonded together. The boards generally have a closed-cell foam core covered by one or more layers adhesively or thermally bonded to the core. In addition, it is desirable to utilizing a stringer embedded in the core to strength the construction of the board.

An example of this is shown in U.S. Pat. No. 4,276,844, which discloses a soft sailboard wherein the only rigid structure of the entire board is a pair of closely spaced fiberglass stringers longitudinally extended along the midline of the board. In particular, a cross section of the board shows that that pair of the stringers are both in an upright position within the core to strengthen the board. However, it is because of the upright manner, the flexibility of the board is reduced.

It has been found in the surfing art that high flexibility in a surfboard or a bodyboard increases the maneuverability of that board so that higher flexibility, buoyancy, and dimensional stability must be combined for greatest control, maximum speed and most effective performance in surfing for pleasure or in competition.

SUMMARY OF INVENTION

The primary object of this invention is therefore to provide a reinforced board which is highly flexible.

It is another object of the present invention to provide a decorated board with improved flexibility combined with dimensional stability.

According to the present invention, a sports board comprises an elongated foam core, a top layer, a bottom layer and at least one flexible flat reinforcement strip embedded in the foam core. The foam core has an upper surface and an opposed lower surface. The top layer is laminated to the upper surface of the foam core and has a riding surface, a thickness less than that of the foam core and a density greater than the foam core. The bottom layer is laminated to the lower surface of the foam core and has a running sole, a thickness less than that of the foam core and a density greater than the foam core. In addition, the reinforcement strip extends substantially parallel to the foam core.

Preferably, the foam core is made of polyethylene foam, which is flexible by itself.

Preferably, the flat reinforcement strip is disposed in a lower half of the foam core proximate to the bottom layer so that the flexibility and dimensional stability are combined.

Preferably, the foam core consists of a plurality of laminated foam layers such that the multi-layered foam core contributes more flexibility than a mono-layered foam core under the same condition of thickness and material.

BRIEF DESCRIPTION OF DRAWINGS

The invention will now be elucidated with reference to the following description and accompanying drawings where:

FIG. 1 is a partial perspective view of a sports board according to a first embodiment of the present invention;

FIG. 2 is a cross-sectional exploded view of the sports board of FIG. 1.

FIG. 3 is a cross-sectional view of a sports board according to a second embodiment of the present invention;

FIG. 4 is a cross-sectional view of a sports board according to a third embodiment of the present invention; and

FIG. 5 is a cross-sectional view of a sports board according to a fourth embodiment of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

With reference to FIGS. 1 and 2, description will be given of a sports board according to a first embodiment of this invention. The sports board 100 mainly comprises an elongated foam core 1, a top layer 2, a bottom layer 3, three flexible flat reinforcement strips 4 embedded in the foam core 1 and a side skin 5.

Referring to FIG. 2, the foam core 1 has an upper surface 101 and an opposed lower surface 121 and is preferably made of high-flexible material, such as polyethylene foam (PE foam) or polypropylene foam (PP foam). In particular, the foam core 1 is composed of three laminated foam layers, namely an upper foam layer 10 having the upper surface 101, an intermediated foam layer 11 and a lower foam layer 12 having the lower surface 121, with same thickness and density. Compared with a mono-layered foam core, the multi-layered foam core 1 of this embodiment provides more flexibility to bounce back while surfing than the mono-layered.

The top layer 2 mainly provides a comfortable surface 24 for riding and is laminated to the upper foam layer 10 of the foam core 1. The top layer 2 includes a first foam skin 21 and two laminated second foam skins 22, 23 with different colors. The first foam skin 21 is directly heat-laminated to the upper surface 101 of the foam core 1 without adhesive. The two second foam skins 22, 23 with identical density and thickness are heat-laminated to the first foam skin 21. In addition, the first foam skin 21 has a density greater than that of the foam core 1, but less than that of the second foam skins 22, 23. Whatever the density of the first foam skin 21 may be, the foam core 1 has the density less than any of the foam skins 21, 22 and 23. For instance, in consideration of the flexibility and the dimensional stability, each of the polyethylene foam layers 10, 11 and 12 may have a density of between about 2 and 3 pcf, and preferably a density of about 2.5 pcf. The first foam skin 21 may have a density of between about 6 and 8 pcf, and preferably a density of about 6.5 pcf. And the second foam skins 22, 23 may have a density of between about 7 and 10 pcf, and preferably a density of about 8 pcf. On one hand the first foam skin 21 strengthens the board 100, and on the other it serves as a buffer connecting the foam core 1 and the second foam skins 22, 23 since the high-density second foam skins 22, 23 may not be easily or endurably stuck on the low-density foam core 1 directly. In addition, the total thickness of the foam skins 21, 22 and 23 is less than that of the foam core 1 so as to provide the board 100 with a comfortable riding surface 24 while retaining a flexible, strong structure. It should be noted that the laminated second foam skins 22, 23 may also be replaced by a mono-layered foam skin with same density and total thickness to serve the same purpose. Alternatively, more than two second foam skins may be applied on the first foam skin 21 if necessary.

Similar to the top layer 2, the bottom layer 3 of the board 100 has a running sole 35 therebottom, a total thickness less than that of the foam core 1 and an average density greater than that of the foam core 1. The bottom layer 3 includes a foam skin 31, a connecting layer 32, a glazed film 33 and a graphic sheet 34.

Similar to the foam skins 21, 22, 23 of the top layer 2, the foam skin 31 of the bottom layer 3 is heat-laminated to the lower surface 121 of the lower foam layer 12 of the foam core 1. Likewise, the foam layer 31 may be mono-layered or multi-layered. The connecting layer 32, made of polyethylene (PE) or other adhesive material, is provided to combine the foam skin 31 with the glazed film 33 in view of material difference between the foam skin 31 and the glazed film 33.

The glazed film 33 is a metallized polyester film which includes a polyester film 331, a metal layer 333, such as an Aluminum, electroplated or coated on the polyester film 331 and a protective film 332, such as a PE film, joined to the polyester film 331. The PE protective film 332 may be joined to the polyester film 331 via a binding solution. In addition, since the connecting layer 32 and the protective film 332 both have the same PE material, they may be directly heat-bonded to each other without adhesive. In such a fashion, the glazed film 33 maybe securely joined to the foam skin 31 and performs a gloss reflective effect while surfing.

The graphic sheet 34 includes a transparent plastic film 342 and a pattern 341 sandwiched between the polyester film 331 of the glazed film 33 and the plastic film 342. That's, the pattern 341 may be printed on either an inner surface of the plastic film 342 or an outer surface of the polyester film 331 of the glazed film 33. In this embodiment, the transparent plastic film 342 is made of polyester, and the pattern 341 is printed on the plastic film 342. Since the plastic film 342 and polyester film 331 of the glazed film 33 have the same material, namely polyester, the pattern 341 can be sandwiched between the two films 331 and 342 by using a heat lamination process, and is visible via the transparent plastic film 342. Preferably, the plastic film 342 has a thickness of at least 0.05 mm for wear and abrasion resistance.

Referring back to FIG. 1, the side skin 5 is joined to edges of the foam core 1. The side skin 5 includes an inner foam skin 51 and a colored outer foam skin 52 laminated to the inner skin 51. The inner and outer foam skin 51, 52 each has a density greater than that of the foam core 1.

Referring to FIGS. 1 and 2, the reinforcement strips 4 are preferably located in a lower half of the foam core 1 proximate to the bottom layer 3 and extend substantially the full length of the foam core 1 and parallel to the foam core 1 for flexibility and balance. Since the foam core 1 is light, its head, together with the whole foam core 1, is easy to be raised while surfing. It is therefore the flexible flat reinforcement strips 4 are embedded in the lower half for bounceback and balance. In this embodiment, the reinforcement strips 4 are sandwiched between the intermediated foam layer 11 and the lower foam layer 12, as best seen in FIG. 2. In addition, a substance may be coated on the reinforcement strips 4 to create a rough surface contacting with the foam core 1 so as to prevent the reinforcement strips 4 from moving relative to the foam core 1.

Further, according to another example, the reinforcement strips 4 may be made of different material combinations with different elasticities so as to define a specific elasticity profile in the sports board for special occasion.

With reference to FIG. 3, a sports board in accordance with a second embodiment of the invention is illustrated. Similar to the first embodiment, the second embodiment comprises a foam core 1, a top layer 2 and a bottom layer 3 except that three flexible flat reinforcement strips 4 are staggered. That is, at least two of the reinforcement strips 4 are placed at different levels with respect to the lower surface of the foam core 1. In such a fashion, another elasticity profile is defined in the sports board.

With reference to FIG. 4, a sports board in accordance with a third embodiment of the invention is illustrated. Similar to the first embodiment, the third embodiment comprises a foam core 1, a top layer 2 and a bottom layer 3 except that the third embodiment includes two flexible flat reinforcement strips 4 and one flexible cylindrical solid or hollow stick 6, instead of the three flat reinforcement strips 4 of the first embodiment. Those strips 4 and the stick 6 are placed at the same level with respect to the lower surface of the foam core 1. In such a fashion, a further specific elasticity profile is defined in the sports board.

With reference to FIG. 5, a sports board in accordance with a fourth embodiment of the invention is illustrated. The sports board comprises a foam core 1 a, a top layer 2 a and a bottom layer 3 a, three flexible flat reinforcement strips 4 a and a side skin 5 a. The reinforcement strips 4 a and the side skin 5 a are similar to those of the first embodiment and will not be discussed herein for simplification. However, unlike the multi-layered foam core 1, the foam core 1 a of the fourth embodiment is a mono-layered and can be easily made from a mold manufacturing process where the reinforcement strips 4 a is positioned in a lower position of the mold. In addition, the foam core 1 a may be made of PE foam, PP foam, PS foam (polystyrene foam), PO foam (PE/ PS foam) or the like. The top layer 2 a laminated to a top surface of the foam core 1 a includes a PE foam skin 21 a and a plastic film 22 a. In particular, the plastic film 22 a may be a mono-layered plastic film or a patterned laminate which includes an inner film, a transparent outer film and a pattern placed in between the inner and outer films. The bottom layer 3 a laminated to a bottom surface of the foam core 1 a includes a PE foam skin 31 a and a plastic board 32 a. The plastic board 32 a may be a patterned laminate as defined in the plastic film 22 a. Alternatively, the plastic board 32 a may further include a thick plastic plate being laminated to the patterned laminate for wear resistance. In this embodiment, the upper and lower PE foam skins 21 a, 31 a have the same thickness which is greater than that of plastic board 32 a. The thickness of the plastic board 32 a is greater than that of the plastic film 22 a.

Numerous characteristics and advantages of the invention have been set forth in the foregoing description. The disclosure, however, is illustrative only, and changes may be made in detail within the principle of the invention, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

1. A sports board comprising: an elongated foam core having an upper surface and an opposed lower surface; a top layer laminated to the upper surface of the foam core and having a riding surface, a thickness less than that of the foam core and a density greater than the foam core; a bottom layer laminated to the lower surface of the foam core and having a running sole, a thickness less than that of the foam core and a density greater than the foam core; and a flexible flat reinforcement strip being embedded in the foam core, and extending substantially the full length of the foam core and parallel to the foam core.
 2. The board set forth in claim 1, wherein the reinforcement strip is disposed in a lower half of the foam core proximate to the bottom layer.
 3. The board set forth in claim 1, wherein the foam core comprises a plurality of laminated foam layers.
 4. The board set forth in claim 1, wherein the foam core comprises a laminated upper foam layer, intermediate foam layer and lower foam layer, and the reinforcement strip is inserted between the intermediate and lower foam layers proximate to the bottom layer.
 5. The board set forth in claim 3, wherein the top layer includes a first foam skin laminated to the upper surface of the foam core and a second foam skin laminated to the first foam skin; and the first foam skin has a density greater than that of the foam core but less than that of the second foam skin.
 6. The board set forth in claim 3, wherein the bottom layer includes a foam skin laminated to the lower surface of the foam core and a glazed film laminated to the foam skin.
 7. The board set forth in claim 3, wherein the foam core comprises a foam selected from a group consisting of polyethylene foam and polypropylene foam.
 8. The board set forth in claim 7, wherein the bottom layer includes a foam skin laminated to the lower surface of the foam core and a glazed film laminated to the foam skin of the bottom layer.
 9. The board set forth in claim 8, wherein the glazed film is a metallized polyester film.
 10. The board set forth in claim 9, wherein the bottom layer further includes a connecting layer interconnecting the glazed film and the foam skin of the bottom layer.
 11. The board set forth in claim 10, wherein the glazed film includes a polyester film, a metal layer coated on the polyester film, and a protective film laminated to the metal layer; and the connecting layer interconnects the protective film of the glazed film and the foam skin of the bottom layer.
 12. The board set forth in claim 10, wherein the connecting layer is made of polyethylene; and the glazed film includes a polyester film, an aluminum layer coated on the plastic film, and a polyethylene protective film laminated to the metal layer; and the connecting layer interconnects the polyethylene protective film of the glazed film and the foam skin of the bottom layer.
 13. The board set forth in claim 12, wherein the bottom layer further includes a transparent plastic film laminated to the glazed film and a pattern printed to either an inner surface of the plastic film or an outer surface of the polyester film of the glazed film.
 14. The board set forth in claim 1, wherein the reinforcement strip is coated with a substance to prevent the reinforcement strip from moving relative to the foam core.
 15. A sports board comprising: an elongated foam core including a laminated upper foam layer, intermediated foam layer and lower foam layer; a first foam skin laminated to the upper foam layer of the foam core and having a density greater than that of the foam core; a second foam skin laminated to the first foam skin and having a riding surface and having a density greater than that of the first foam skin; a third foam skin laminated to the lower foam layer of the foam core; a flexible flat reinforcement strip being embedded between the intermediated and lower foam layers of the foam core, and extending substantially the fuill length of the foam core and parallel to the foam core; a metallized polyester film attached to the third foam skin; a plastic film laminated to the metallized polyester film; and a pattern printed on either the plastic film or the metallized polyester film.
 16. The board set forth in claim 15, wherein the reinforcement strip is coated with a substance to prevent the reinforcement strip from moving relative to the foam core.
 17. A sports board comprising: an elongated foam core having an upper surface and an opposed lower surface; a top layer laminated to the upper surface of the foam core and having a riding surface, a thickness less than that of the foam core and a density greater than the foam core; a bottom layer laminated to the lower surface of the foam core and having a running sole, a thickness less than that of the foam core and a density greater than the foam core; and a plurality of flexible flat reinforcement strips having different elasticities, being embedded in the foam core, and extending substantially the fuill length of the foam core and parallel to the foam core.
 18. The board set forth in claim 17, wherein the reinforcement strips are disposed in a lower half of the foam core proximate to the bottom layer.
 19. The board set forth in claim 18, wherein the reinforcement strips are placed at the same level with respect to the lower surface of the foam core.
 20. The board set forth in claim 17, wherein the reinforcement strips are placed at different levels with respect to the lower surface of the foam core. 